Apparatus and method of regulating the speed of a brushless DC motor

ABSTRACT

A control circuit is provided for regulating the rotational speed of a brushless DC motor by pulse width modulating at least one power transistor to pass a motor supply signal to the motor armature. A voltage averaging circuit generates an averaged signal indicative of the average voltage level being supplied to the motor. The averaged voltage signal is compared against a reference voltage to determine motor speed error in order to maintain the rotational speed of the motor at a generally constant level. A sawtooth or other periodic ramp signal is added to a motor current signal, and this composite signal is monitored by a comparator until it overcomes the motor speed error signal. The pwm circuit thereby modulates the power supply to regulate motor speed while maintaining a symmetrical motor armature current waveform. The control circuit takes advantage of the inherent inductance of the motor windings and the moment of inertia of the rotor assembly as filters to help smooth the physical operation of the motor and to further maintain its desired rotational speed.

CROSS-REFERENCE TO RELATED APPLICATION

This patent application is a continuation of U.S. patent applicationSer. No. 09/396,396, filed Sep. 15, 1999, now U.S. Pat. No. 6,285,146,which is a continuation-in-part of U.S. patent application Ser. No.09/131,046, filed Aug. 7, 1998, now U.S. Pat. No. 6,188,187, each ofwhich is co-pending herewith, and is incorporated by reference herein.

FIELD OF THE INVENTION

The present invention relates generally to a motor controller, and moreparticularly to a controller for controlling the rotational speed andarmature current of a brushless DC motor.

BACKGROUND OF THE INVENTION

Control circuits are known for controlling brushless DC motors, such as,for example, regulating the rotational speed of brushless DC fan motorsthat cool the interiors of computers. One problem with brushless DC fanmotors is that they traditionally have had a narrow usable input range.Fan speed and input current are approximately proportional to inputvoltages. Thus, if the input voltage from an unregulated source such asa battery were used to power a brushless DC fan, such as a typical 24volt nominal battery, the voltage would vary from about 28 volts infloat state to about 21 volts in discharged state. This change wouldcause a brushless DC fan rated at a nominal 3500 RPM to vary as much asabout 1000 RPM over the above-mentioned range of battery voltages. Sucha large variation in RPM means that the fan is not properly cooling acomputer at the low-end of the RPM range, and that power is being wastedat the high-end of the RPM range.

Some brushless DC fan users have multiple input source voltages thattheir equipment is expected to operate from, with 24 volt and 48 voltsystems being the most common. Such multiple source voltages pose thesame problem in resultant RPM variation in a brushless DC fan motor asdoes a single input voltage source whose voltage level varies widely.Accordingly, there is a need to provide a brushless DC fan motor havinga high input range with relatively little variation in motor rotationalspeed. For example, in the telecommunications industry, there is a needto provide a brushless DC fan motor having an input range of about 20-60volts with little variation in motor rotational speed. However, otherinput voltage ranges may be provided for other motor applications.

Linear regulators have been used to regulate brushless DC fan rotationalspeed. However, the linear regulator approach poses an efficiencyproblem. A brushless DC fan that draws 18 watts at 21 volts will drawalmost 27 watts when operating at 28 volts, and 54 watts at 56 voltsinput, with the increase in power draw having to be dissipated as heat.

Pulse width modulation (“pwm”) has also been used in the prior art toregulate motor speed. One method commonly used is to pulse widthmodulate the commutation transistors to the brushless DC motor. Thisemployment of pulse width modulation reduces the dissipation of energyinvolved with changing motor speed. However, pulse width modulating thecommutation transistors does not permit large changes in input voltagewithout widely varying the rotational speed of the brushless DC motor.This method is most commonly used in thermal brushless DC fans to reducebrushless DC fan speed at low temperatures. The speed variation isunfortunately even wider than that of the non-speed controlled type, andclamp dissipation is still relatively high.

Another pwm approach is to use a fill bridge driver. This involvesplacing a bipolar motor winding between the legs of four switchingtransistors and controlling the timing of the pwm modulator andcommutation logic to regulate motor current. Wide input voltage rangesare possible with high efficiency. A well designed full bridge drivercan regulate motor speed over a better than 3:1 range of input voltage.The chief drawbacks are complicated logic and the difficulties ofdriving the four switching transistors without cross conduction throughthe series connected pairs. Although many manufacturers offer integratedfull bridge devices, most suffer from a limitation of current and/orvoltage.

Another approach is to employ a pwm switching voltage regulator toaccommodate a wide range of input voltages without widely varying therotational speed of the motor. However, this requires relatively bulkyfilter inductors and capacitors.

Of the above-mentioned pwm approaches, the pwm voltage regulatorregulates motor voltage. The other methods typically regulate motorcurrent. Voltage regulation is preferred to minimize variations indesired brushless DC motor speed. In other words, the variation in motorspeed from motor to motor for a given current is greater than thevariation in motor speed for a given voltage. Additionally, motor torqueis a function of motor current. Therefore, if motor current is reducedin order to reduce motor speed to a low value, the motor torque becomeslow. This means that the motor speed is sensitive to applied load (i.e.,back pressure). This sensitivity to back pressure results in large speeddeviations from the desired value. Motor-starting at low desired speedsis also a problem in that if the motor current is set too low then themotor will not be able to overcome the magnetic detents used to positionthe rotor away from the null point. Unfortunately, controlling motorvoltage while failing to control motor current to adhere to asymmetrical waveform has the potential to increase vibration andelectrical interference.

Fans typically use one of two types of two-phase DC brushless motors,unipolar or bipolar. The difference between the two types is that aunipolar motor energizes two opposing poles of the four poles available,whereas a bipolar motor will energize all four poles at the same time,with the coils in quadrature having opposite magnetic polarity. Simplystated the unipolar type uses two pairs of coils with one pair energizedand the other pair not energized, with the poles always energized in thesame polarity. The bipolar motor energizes the four poles at the sametime with adjacent poles having opposite polarity. Rotation of the motorof the unipolar type is accomplished by alternating energized pairswhile the bipolar motor changes the polarity of the four poles.

The bipolar motor has double the output of the unipolar motor becauseall of the copper is utilized and all four poles act upon the magnet.Drive complexity is greater as the direction of current must be reversedrather than just interrupted. In both cases however a problem ofasymmetrical current in the motor exists. The current in the motorwindings is reversed twice for each complete revolution of the bipolarmotor. Various factors influence or modify the symmetry of the motorsuch as the degree of magnet strength, offset in the position sensor,mechanical variations in the motor components, and variations in wireresistance. This causes the current levels and the waveform shapes todiffer from each other within a rotational period and allow differenttorques to be applied to the rotor, increasing vibration and noise.Accordingly, it would be desirable to provide an apparatus and methodwhich may correct such non-ideal behavior in both unipolar and bipolarmotors.

It is also an object of the present invention to provide a brushless DCmotor regulator which handles a relatively wide range of input voltageswith little variation in the rotational speed of the motor.

It is another object of the present invention to provide a brushless DCmotor regulator which controls motor armature current to a substantiallysymmetrical waveform.

It is a further object of the present invention to provide a brushlessDC motor regulator that eliminates the relatively bulky filtercapacitors and inductors interfacing the regulator and motor.

The above and other objects and advantages of the present invention willbecome more readily apparent when the following detailed description isread in conjunction with the accompanying drawings.

SUMMARY OF THE INVENTION

According to one aspect of the present invention a control circuit forcontrolling the rotational speed of a brushless DC motor is provided.The control circuit includes an electrical conduction switch having aninput, an output, and a control terminal for passing a motor supplysignal to a brushless DC motor from a voltage across first and secondterminals of a DC voltage source. The input terminal of the switch is tobe coupled to the first terminal of the DC voltage source, and theoutput terminal of the switch is to be coupled to the first terminal ofthe brushless DC motor. A voltage averaging circuit is provided havingfirst and second input terminals and an output terminal for averagingthe voltage level of the motor supply signal. The first input terminalof the voltage averaging circuit is coupled to the output of the switch,and the second terminal of the voltage averaging circuit is to becoupled to the second terminal of the voltage source. A differentialamplifier has first and second input terminals and an output terminalfor generating a signal corresponding to motor speed error. The firstinput terminal of the differential amplifier is coupled to a voltagereference potential indicative of the desired motor speed, and thesecond input terminal of the differential amplifier is coupled to theoutput terminal of the voltage averaging circuit.

A pulse width modulator (“pwm”) of the control circuit has first andsecond input terminals and an output terminal. The first input terminalof the pwm is coupled to the output terminal of the differentialamplifier for receiving the signal corresponding to motor speed error,the second input terminal of the pwm is coupled to a signalcorresponding to the change in motor current, and the output terminal ofthe pwm is coupled to the control terminal of the electrical conductionswitch. The pwm turns the switch on at a periodic rate, and turns theswitch off after a delay, or pulse width, indicative of the differencein voltage level between the signal corresponding to motor speed errorand the signal corresponding to change in motor current, in order toprovide a motor supply signal having a substantially constant averagevoltage level corresponding with the desired motor speed and asubstantially symmetrical current waveform. Preferably, the motorwindings serve as an inductive filter to help smooth changes in current,and the rotor mass of the motor serves to help smooth the rotationalspeed of the motor.

According to another aspect of the present invention, a control circuitfor controlling the rotational speed of a brushless DC motor isprovided. The control circuit includes first means to be coupled to anelectrical power source for switchably passing a motor supply signal toa brushless DC motor. A second means is coupled to an output of thefirst means for generating an averaged signal by averaging the voltageof the motor supply signal. A third means is coupled to an output of thefirst means for generating a signal indicative of the change in motorcurrent. A fourth means is coupled to an output of the second means forgenerating a speed error signal having a voltage level indicative of thedifference in voltage between the voltage level of the averaged signalof the second means and a reference voltage. A fifth means turns on thefirst means periodically, and turns off the first means following adelay corresponding to the difference between the value of the speederror signal and the value of the change in motor current signal. Thesemeans provide a substantially constant average motor supply voltagelevel resulting in a substantially constant motor speed approximatelyequal to a desired motor speed, and a substantially symmetrical motorcurrent supply signal waveform.

According to yet another aspect of the present invention, a method ofcontrolling the rotational speed of a brushless DC motor is provided. Amotor supply signal is switchably passed from an electrical power sourceto a brushless DC motor. The voltage level of the motor supply signal isaveraged to form an averaged signal. An error signal is generated havinga voltage level indicative of the difference in voltage between theaveraged signal and a reference voltage. A motor current signal isgenerated having a voltage level indicative of the change in current ofthe motor supply signal. The motor supply signal is modulated inresponse to the difference in value between the error signal and themotor current signal in order to provide a substantially constantvoltage level and a substantially symmetrical motor current waveform.

According to another aspect, the present invention is directed to amethod of regulating the rotational speed of a DC brushless motor,wherein the motor has at least one input terminal, a plurality of motorwindings electrically coupled to the at least one input terminal, and arotor defining a rotor mass and electromagnetically coupled to the motorwindings and rotatable by interaction with an electromagnetic fieldgenerated by current flowing through the motor windings. The methodcomprises the following steps:

(i) passing motor supply signals from an electrical power source throughan electrical conduction switch having an input, an output, and acontrol terminal;

(ii) pulse width modulating the motor supply signals passing through theelectrical conduction switch and generating pulse width modulated motorsupply signals;

(iii) transmitting the pulse width modulated motor supply signalsthrough a substantially inductorless path extending from the output ofthe electrical conduction switch to the at least one input terminal;

(iv) using the windings of the motor to integrate the pulse widthmodulated motor supply signals and function as an inductor filter tosmooth the current level of the motor supply signals; and

(v) using the rotor mass as a filter capacitor to smooth the voltagelevel of the motor supply signals.

According to yet another aspect, the present invention is directed to acontrol circuit for regulating the rotational speed of a DC brushlessmotor, wherein the motor has at least one input terminal, a plurality ofmotor windings electrically coupled to the at least one input terminal,and a rotor defining a rotor mass and electromagnetically coupled to themotor windings and rotatable by interaction with an electromagneticfield generated by current flowing through the motor windings. Thecontrol circuit comprises an electrical conduction switch having aninput, an output, and a control terminal for passing a motor supplysignal to the DC brushless motor from a voltage across first and secondterminals of a DC voltage source. The input terminal of the switch iscoupled to the first terminal of the DC voltage source, and the outputterminal of the switch is coupled to the at least one input terminal ofthe motor. A substantially inductorless path extends from the output ofthe electrical conduction switch to the at least one input terminal ofthe motor. A pulse width modulator has an output terminal coupled to thecontrol terminal of the electrical conduction switch for pulse widthmodulating the motor supply signals passing through the electricalconduction switch and generating pulse width modulated motor supplysignals. The pulse width modulated motor supply signals are transmittedthrough the substantially inductorless path extending from the output ofthe electrical conduction switch to the at least one input terminal. Thewindings of the motor integrate the pulse width modulated motor supplysignals and function as an inductor filter to smooth the current levelof the motor supply signals. And the rotor mass functions as a filtercapacitor to smooth the voltage level of the motor supply signals.

One advantage of the preferred embodiments of the present invention isthat the motor voltage signal is compared against the reference voltageto generate an error signal, and the error signal is in turn comparedagainst the motor current signal to pulse width modulate the motor inputsignal. Accordingly, the preferred embodiments of the apparatus andmethod of the present invention employ both a voltage feedback loop, anda current feedback loop embedded within the voltage feedback loop tomaintain a substantially constant motor speed over a wide range of powersupply voltages, to accurately select and control motor speed, and to doso while maintaining a substantially symmetrical armature currentwaveform.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates schematically a prior art electrical circuit of a pwmvoltage regulator employing filter capacitors and inductors interfacingthe regulator to a brushless DC motor.

FIG. 2 illustrates schematically an electrical circuit of a pwm voltageregulator for a unipolar motor embodying the present invention whichemploys the brushless DC motor windings and rotor mass as a substitutefor additional filter inductors and capacitors.

FIG. 3 illustrates schematically a pwm sub-circuit of the pwm voltageregulator of FIG. 2.

FIG. 4 illustrates schematically an alternative current compensating pwmsub-circuit embodying the present invention and which may form a part ofthe pwm voltage regulator of FIG. 2.

FIGS. 5A-5C illustrate three current waveform inputs to a motordemonstrating typical waveform improvements of the pwm sub-circuit ofFIG. 4 when used in the pwm voltage regulator of FIG. 2.

FIG. 6 illustrates schematically an electrical circuit of a pwm voltageregulator for a bipolar motor embodying the present invention and whichalso employs the brushless DC motor windings and rotor mass as asubstitute for additional filter inductors and capacitors.

FIG. 7 illustrates schematically a current compensating pwm controlcircuit embodying the present invention for the pwm voltage regulator ofFIG. 6.

FIGS. 8A-8B illustrate two current waveform inputs to a motor operatingat about 2000 RPM demonstrating typical waveform improvements of the pwmcircuit of FIG. 7 when used with the pwm voltage regulator of FIG. 6.

FIGS. 9A-9B illustrate two current waveform inputs to a motor operatingat about 3500 RPM demonstrating typical waveform improvements of the pwmcircuit of FIG. 7 when used with the pwm voltage regulator of FIG. 6.

FIGS. 10A-10B illustrate two motor winding current waveforms in a motoroperating at about 2000 RPM demonstrating typical waveform improvementsof the pwm circuit of FIG. 7 when used with the pwm voltage regulator ofFIG. 6.

FIGS. 11A-11B illustrate two motor winding current waveforms in a motoroperating at about 3500 RPM demonstrating typical waveform improvementsof the pwm circuit of FIG. 7 when used with the pwm voltage regulator ofFIG. 6.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

A prior art pwm voltage regulator will first be explained as backgroundto the pwm voltage regulator embodying the present invention. Referringnow to the prior art of FIG. 1, a pwm voltage regulator is indicatedgenerally by the reference number 10 and is employed to control therotational speed of a brushless DC motor 12 enclosed by dashed lines.The regulator 10 includes a positive terminal 11 and a negative terminal13 for receiving a regulator DC input voltage from a power source (notshown). The pwm voltage regulator 10 includes an input filter2(capacitor 14, a pwm power transistor 16 that is switched on and off bya pwm modulator 18, a catch diode 20, and an output filter circuit 22enclosed by dashed lines which includes an output filter inductor 24 andan output filter capacitor 26. The output filter inductor 24 and theoutput filter capacitor 26 are typically rather bulky, thereby imposingdesign constraints in relation to the increasing demand for smallervoltage regulators that are either separate from or incorporated inbrushless DC motors. The demand for smaller regulated motors isparticularly high in the computer industry which uses DC fan unitsincorporating regulated brushless DC motors for cooling electroniccomponents.

The output filter circuit 22 smoothes a pwm waveform generated by thepwm modulator 18 and the switching transistor 16 into a motor supplysignal having an average DC voltage level. This average DC voltage levelof the DC motor input signal determines the rotational speed of themotor 12. In order to maintain the rotational speed of the brushless DCmotor at a generally constant revolutions per minute (rpm), feedback isprovided to the regulator 10. To provide feedback, the voltage level ofthe DC motor input signal is received at the inverting input of adifferential or error amplifier 28 and compared with a reference voltageV_(ref) which is provided at the non-inverting input of the amplifier28. The output of the error amplifier 28 is the difference between thetwo inputs to the error amplifier 28, and is multiplied by the gain ofthe error amplifier. This error voltage output by the error amplifier 28is provided as a feedback signal to the pwm modulator 18 which adjuststhe width of the pulse or modulator signal generated by the pwmmodulator. The modulator signal adjusts the switching on and off time ofthe transistor 16 in order to modulate the regulator input signal, whichin turn adjusts the average voltage level of the motor input signalafter being smoothed by the filter circuit 22, in order to compensatefor deviations in the motor input voltage level sensed by the feedbackcircuitry. The compensation thus tends to maintain the voltage level ofthe motor input signal constant despite changes in the voltage level ofthe regulator input signal or changes to the load in order that therotational speed of the motor 12 remains relatively constant. Aspreviously mentioned, a drawback with the prior art circuit is that theoutput filter inductor and capacitor 24, 26 are relatively bulky andtherefore require considerable mounting space in the regulatorcircuitry. This large space requirement hampers the growing demand toincorporate brushless DC motors and regulator circuitry in ever smallerspaces, such as the relatively small spaces allotted for regulated DCcooling fan units within portable computers.

Turning now to FIG. 2, a pwm voltage regulator circuit 100 is employedin a center tap modulation approach for regulating the rotational speedof a brushless DC motor 102 enclosed by dashed lines. The motor 102 is aconventional brushless DC motor which may be coupled to a fan 104 usedto cool a surrounding area such as the inside of a computer. The motor102 includes first and second directional windings 106, 108,respectively. Each of the windings 106, 108 has a first end coupled toan input terminal or center tap 110 of the motor. A second end 112 ofthe first winding 106 is coupled to ground potential via a firstcommutation switching transistor 114, and a second end 116 of the secondwinding 108 is likewise coupled to ground via a second commutationswitching transistor 118. The switching transistors 114, 118 arealternately turned on and off by means of a conventional commutatorlogic circuit 120. A rotor 122 is caused to rotate, and in turn rotatethe fan 104 coupled thereto, by interacting with an electromagneticfield generated by commutated current flowing through the first andsecond windings 106,108.

The voltage regulator circuit 100 includes a positive input terminal 124and a negative input terminal 126 for receiving thereacross a DCregulator input signal from a power source (not shown). An inputcapacitor 128 is coupled across the positive and negative inputterminals 124 and 126. Means for switchably passing a motor supplysignal to the brushless DC motor 102 includes, for example, a pwm poweror switch or transistor 130, such as an npn bipolar junction transistor(BJT). The transistor 130 has its collector 132 coupled to the positiveinput terminal 124 and its emitter 134 coupled to an input voltageterminal of the motor 102 at 110. A catch diode 135 has its cathodecoupled to the emitter 134 of the transistor 130 and its anode coupledto ground potential. Means for averaging the voltage of the motor supplysignal includes a series connected resistor 136 and capacitor 138 whichcooperate to form a voltage integrator. The resistor 136 and thecapacitor 138 are coupled between the emitter 134 of the transistor 130and the negative input terminal 126. More specifically, the resistor 136has respective first and second terminals 139, 140, and the capacitor138 has respective first and second terminals 141, 142. The firstterminal 139 of the resistor 136 is coupled to the emitter 134 of thetransistor 130. The second terminal 140 of the resistor 136 is coupledto the first terminal 141 of the capacitor 138 at a junction 144 wherean averaged signal indicative of the average voltage level of the motorsupply signal is generated, and the second terminal 142 of the capacitor138 is coupled to the negative input terminal 126.

Means for generating a differential signal having a voltage levelindicative of the difference between the voltage level of the averagedsignal and a reference voltage includes a high gain operational or erroramplifier 146, such as a differential voltage amplifier. The erroramplifier 146 has its inverting input coupled to the junction 144 via aresistor 147. The gain of the error amplifier 146 is preferably selectedso that only millivolts of difference between the inverting andnon-inverting inputs will drive the amplifier output to its extreme. Aresistor 149 is coupled between the inverting input of the erroramplifier 146 and ground potential. The non-inverting input of the erroramplifier 146, which is fed the reference voltage, is coupled to avoltage V_(cc) via a resistor 151. The non-inverting input is alsocoupled to ground via a series connected resistor 153 and potentiometer155. An output 148 of the error amplifier 146 is coupled to a pulsewidth modulator (pwm) 150 at an input 152. The pwm 150 is a means forturning on and off the transistor 130 to modulate the motor supplysignal so that the motor supply signal is maintained at a substantiallyconstant voltage level and, in turn, the motor 102 is maintained at asubstantially constant rotational speed. A roll-off capacitor 157 iscoupled between the inverting input and the output 148 of the erroramplifier 146. An output 154 of the pwm 150 is coupled to a base 156 ofthe transistor 130.

One preferred embodiment of the pulse width modulator 150 is illustratedin FIG. 3. The pwm 150 includes an oscillator sub-circuit 200 and adriver sub-circuit 300 each enclosed by dashed lines. The oscillator 200includes a comparator 202 having its non-inverting input coupled to aV_(cc) source at 204 via a resistor 206. An output 208 of the comparator202 is coupled to its non-inverting input via a resistor 210. A resistor212 is coupled between the non-inverting input of the comparator 202 andground potential. The resistors 206, 210 and 212 are coupled to oneanother at a junction 214. A timing resistor 216 is coupled between theoutput 208 of the comparator 202 and the inverting input of thecomparator. A timing capacitor 218 is coupled between the invertinginput of the comparator 202 and ground potential.

The driver sub-circuit 300 includes a comparator 302 having itsnon-inverting input coupled to the inverting input of the comparator 202of the oscillator sub-circuit 200. The inverting input of the comparator302 at terminal 304 receives the error voltage signal from the output148 of the error amplifier 146 shown in FIG. 2. An output 306 of thecomparator 302 is coupled to a base of a transistor 308 via a resistor314. The transistor 308, which serves as a pwm driver transistor, isshown as an npn BJT, but may be an FET or other suitable transistor fordriving the pulse width modulator. An emitter of the transistor 308 iscoupled to ground potential, and a collector of the transistor 308 iscoupled at its output 310 to the base 156 of the power transistor 130shown in FIG. 2.

Referring now to the operation of the pwm voltage regulator circuit 100shown in FIG. 2, the regulator circuit 100 receives a DC regulator inputsignal across the positive and negative input terminals 124, 126 from apower source (not shown) such as a DC power supply or an AC source thatis rectified into DC voltage. The DC regulator input signal is initiallyfiltered by the input capacitor 128 to further smooth the input voltagesignal and to remove any unwanted transient voltage fluctuations. Themotor supply signal derived from the DC power supply is modulated by thecombination of the pwm 150 and the transistor 130 to generate a motorsupply signal having a predetermined average voltage level suitable foroperating the motor 102 at a desired rotational speed. Because therotational speed of the motor 102 is a function of the voltage level ofthe motor supply signal, it is important to maintain this voltage levelat substantially the same value.

The pwm 150 sends a modulator signal to the base 156 of the switchingtransistor 130 to modulate the motor supply signal. The modulated motorsupply signal present at the emitter 134 of the transistor 130 is thesignal used to regulate the rotational speed of the motor 102. Thevoltage level of the modulated motor supply signal is averaged at thejunction 144 by the series combination of the resistor 136 and thecapacitor 138 to form an averaged signal, and is thus indicative of theaverage voltage level of the motor supply signal. The voltage level ofthe averaged signal is a function of the pulse width of the modulatedmotor supply signal.

The voltage level of this averaged signal at the junction 144 is reducedby the resistors 147, 149, and this reduced voltage level of theaveraged signal is received at the inverting input of the erroramplifier 146 and compared with a reference, such as V_(ref), togenerate a differential or error signal at the output 148 of the erroramplifier 146. V_(ref) is determined by the resistors 151, 153 andadjusted by the potentiometer 155. The reference voltage V_(ref) is afixed voltage level which is compared with the reduced voltage level ofthe averaged signal to determine if there is any deviation in thedifference between the voltage level of V_(ref) and the reduced voltageof the averaged signal representing the motor supply signal or voltage,and thus indicating a tendency for the rotational speed of the motor 102to change or drift over changes in input voltage to the pwm voltageregulator circuit 100. As an example, the voltage level of the averagedsignal V_(m) is selected as 12.75 volts, V_(ref) is 0.25 volt and theresistors 147, 149 are selected to reduce the voltage level of theaveraged signal by a factor of 50 in order that V_(m)=((resistance ofthe resistor 147/resistance of the resistor149)*V_(ref))+V_(ref)=((50)*0.25)+0.25)=12.75 volts.

If there is a deviation between the ideal voltage V_(ref) (i.e., 0.25volt in this example) and that of the voltage level of the reducedaveraged signal at the inverting input of the error amplifier 146, theerror amplifier 146, in order to compensate for any change in thevoltage level of the motor supply signal (i.e., a deviation from 12.75volts in this example), will generate an error signal at the output 148of the amplifier 146 having a voltage magnitude proportional to thedifference between the voltage levels present at the inverting andnon-inverting inputs of the amplifier 146. When the reduced voltagelevel of the averaged signal drops slightly in relation to V_(ref)because of, for example, a load increase or input voltage drop, thevoltage level of the amplifier signal generated at the output 148 of theamplifier 146 will increase slightly. The increased voltage level of theamplifier signal will then be fed to the input 152 of the pwm 150 toslightly increase the duration or pulse width of the modulator signalgenerated at the output 154 of the pwm 150.

The increased duration of the modulator signal is fed to the base 156 ofthe power transistor 130 to increase the pulse width or duration of theturn-on time of the transistor 130. The increased turn-on time thusincreases the pulse width of the modulated motor supply signal presentat the emitter 134 of the transistor 130 which is fed to the inputvoltage terminal 110 of the brushless DC motor 102. The increasedduration or pulse width of the modulated motor supply signal raises theaverage voltage level of the motor supply signal, to compensate for theslight drop in the voltage level of the motor supply signal, therebymaintaining the rotational speed of the motor at a generally constantrpm. Conversely, if the reduced voltage level of the averaged signalincreases slightly, the amplifier 146, the pwm 150 and the transistor130 cooperate in a fashion opposite to that just described to decreasethe pulse width of the motor supply signal for decreasing the averagevoltage level of the motor supply signal. The roll-off capacitor 157 iscoupled across the error amplifier 146 to prevent the output of theerror amplifier from slewing to its limits in response to V_(m) changesby means of reducing the high frequency gain of the error amplifier 146to the point that the pwm 150 can follow the error amplifier output. Thecatch diode 135 prevents the inductor current from decaying at a rapidrate and the voltage at the center tap 100 from falling below groundpotential in order to maintain the average voltage at the center tap asthe motor current is being commutated.

The pwm voltage regulator circuit just described is known tosubstantially maintain the rotational speed of a brushless DC motor overa wide range of motor supply voltages while also maintaining asymmetrical current waveform. An example of motor rotational speed andcurrent as a function of motor supply voltage is set forth in Table 1.

TABLE 1 Voltage Speed (RPM) Current (Amperes) 19 3680 0.82 20 3180 0.8621 3210 0.84 30 3230 0.61 48 3230 0.41 60 3230 0.35

As can be seen from Table 1, over a motor supply voltage range of 20volts to 60 volts, the rotational speed of a brushless DC motorcontrolled by the regulator circuit of the present invention ismaintained substantially constant (i.e., the rotational speed varies1.5%) as compared with conventional motors. As also shown in the Table,the rotational speed of the motor shows no discernible fluctuation overa motor supply voltage range of 30 to 60 volts.

An advantage of employing the above-described voltage mode control for abrushless DC motor is that the control permits a high torque forstarting the motor and a narrow speed for distribution range for tightlyregulating the rotational speed of the motor over a large range of motorsupply voltages. A further advantage of applying center tap modulationis that this type of modulation possesses the superior linear transfercharacteristics found in full bridge modulation without certaindrawbacks of full bridge modulation, including: the complexity of logicand sequencing of transistor switches, the possibility of crossconduction, and in turn, short circuiting across the input source,difficulty in sensing average motor coil voltage, sensing continuousmotor current, and the high parts count inherent in employing fullbridge modulation.

The operation of the pwm 150 of FIG. 2 will be explained more fully withreference to FIG. 3. Preferably, the resistors 206, 210 and 212 areselected to be of equal resistance. When the output of the comparator202 is low, the junction 214 of the resistors 206, 210 and 212 is at ⅓V_(cc). When the output of the comparator 202 is high, the junction isat ⅔ V_(cc). The timing capacitor 218 is charged and discharged between⅓ V_(cc) and ⅔ V_(cc) by the timing resistor 216. The frequency ofoscillation is primarily a function of the capacitance level of thetiming capacitor 218 and the resistance level of the timing resistor216, and the duty cycle is preferably about 50%. A ramp voltagegenerated by the timing resistor 216 and the timing capacitor 218 isapplied to the non-inverting input of the comparator 302 of the driversub-circuit 300. When the collector of the driver transistor 308 is low,the pwm switch transistor 130, shown in FIG. 2, is off ornon-conducting, and the center tap 110 of the motor 102 is at 0 volts.When the collector of the driver transistor 308 is high, then the pwmswitch transistor 130 is on or conducting, and the center tap 110 of themotor 102 is coupled to V_(in).

As can be seen in FIG. 2, there is no filter circuit external of themotor 102 for smoothing the voltage level of the motor supply signal inorder to maintain the rotational speed of the motor 102 at a generallyconstant rpm. The regulator 100 uses the windings 106, 108 of the motor102 to integrate the pwm voltage and to function similarly to the filterinductor 24 of FIG. 1, and changes in current drawn by the motor 102 aresmoothed (i.e., the rotational speed of the motor is maintainedsubstantially constant) by the mass of the rotor 122 in a similar way asthe filter capacitor 26 of FIG. 1 smoothes the voltage level of themotor input signal. In other words, the motor inductance is substitutedfor the filter inductor 24 of FIG. 1, and the rotor mass or inertia issubstituted for the filter capacitor 26 of FIG. 1. Thus, the bulkyfilter inductor 24 and the filter capacitor 26 of FIG. 1 are eliminatedin the embodiment of FIG. 2. As a result, the regulator 100 consumesconsiderably less space than did prior regulators using bulky filterinductors and capacitors. Further, a regulated DC motor or DC fan unitthat includes the regulator circuit embodying the present invention alsoconsumes less space because of the elimination of the additional bulkyfilter components. Accordingly, the regulator circuit 100, or a DC motoror DC fan unit incorporating the regulator embodying the presentinvention overcomes the space constraints that are found in the prior DCmotors or DC fan units using additional filter components.

Turning to FIG. 4, another preferred embodiment of the pulse widthmodulator is indicated generally by the reference numeral 150′. The pwm150′ includes a periodic sub-circuit 400 and a driver sub-circuit 500each enclosed by dashed lines. The periodic sub-circuit 400 comprises aperiodic signal generator in the form of an oscillator comprising acomparator 402 and related circuit components. The comparator 402 hasits non-inverting input coupled to a V_(cc) source at 404 via a resistor406. An output 408 of the comparator 402 is coupled to its non-invertinginput via a resistor 410. A resistor 412 is coupled between thenon-inverting input of the comparator 402 and ground potential. Theresistors 406, 410 and 412 are coupled to one another at a junction 414.A timing resistor 422 is coupled between the output 408 of thecomparator 402 and the cathode end of a diode 420. The anode end of thediode 420 is coupled to the inverting input of the comparator 402. Atiming resistor 416 is coupled between the output 408 and the invertinginput of the comparator 402. A timing capacitor 418 is coupled betweenthe inverting input of the comparator 402 and ground potential. Aresistor 424 is coupled between the inverting input of the comparator402 and a summing junction 430. As described in further detail below,the periodic signal generator transmits a ramp signal to the junction432 defining a sawtooth waveform. However, as may be recognized by thoseskilled in the pertinent art based on the teachings herein, the periodicsignal generator may generate any of numerous different periodic or rampsignals suitable for performing the functions described herein.Similarly, the periodic signal generator may take any of numerousdifferent configurations which now or later become known to thoseskilled in the pertinent art for performing the functions of theperiodic signal generator described herein.

Means for receiving a motor current sample signal are provided by aninput terminal 428. The input terminal 428 may be coupled, for example,to the common source terminal of the motor MOSFETs of FIG. 2. However,as may be recognized by those skilled in the pertinent art based on theteachings herein, the input terminal 428 may be coupled to any ofnumerous other motor current sources for generating the motor currentsignal described herein. A resistor 426 is coupled between the inputterminal 428 and the summing junction 430. Accordingly, the summingjunction 430 provides a signal indicative of the sum of the periodic orramp signal received from junction 432 and the motor current signalreceived from the input terminal 428.

The driver sub-circuit 500 includes a comparator 502 having itsnon-inverting input coupled to the summing junction 430 of the periodicsub-circuit 400. The inverting input of the comparator 502 receives atterminal 504 the error voltage signal from the output 148 of the erroramplifier 146 of FIG. 2. An output 506 of the comparator 502 is coupledto a Reset input of an RS flip-flop 512. The Set input of flip-flop 512is coupled to the output 408 of the periodic sub-circuit 400. Theinverting output of the flip-flop 512 is coupled through a resistor 514to the base of a transistor 508. An emitter of the transistor 508 iscoupled to ground potential, and a collector of the transistor 508 iscoupled at its output 510 to the base 156 of the power transistor 130 ofFIG. 2. The transistor 508, which serves as a pwm driver transistor, isshown as an npn BJT, but may be an FET or other suitable transistor orother electrical conduction switch for driving the pulse width modulatorof the invention. Similarly, as may be recognized by those skilled inthe pertinent art based on the teachings herein, the flip-flop 512 maytake the form of any of numerous binary state or like devices which nowor later become known to those skilled in the pertinent art forperforming the functions of the flip-flop described herein.

The resistors 406, 410 and 412 may be selected to be of equalresistance. Accordingly, when the output of the comparator 402 is low,the junction 414 of the resistors 406, 410 and 412 is at ⅓ V_(cc), Whenthe output of the comparator 402 is high, the junction 414 is at ⅔V_(cc). The timing capacitor 418 is periodically charged from ⅓ V_(cc)to ⅔ V_(cc) by the timing resistor 416. The timing capacitor 418 isperiodically discharged from ⅔ V_(cc) to ⅓ V_(cc) by the timing resistor422 through diode 420. The frequency of oscillation is primarily afunction of the capacitance level of the timing capacitor 418 and theresistance levels of the timing resistors 416 and 422. Timing resistor416 determines the charge period, and the equivalent resistance ofparallel resistors 416 and 422 determines the discharge period.Accordingly, a ramp voltage generated by the timing resistor 416 and thetiming capacitor 418 is applied to the junction 432 and, in turn, to thesumming junction 430. Input terminal 428 passes a motor current signalacross resistor 426 to summing junction 430. Thus, the resultant signalat the summing junction 430 is approximately equal to the sum of theramp signal and the motor current signal, and the summed signal iscoupled to the non-inverting input of the comparator 502 of the driversub-circuit 500. The output terminal 506 of the comparator 502 iscoupled to the Reset input of flip-flop 512, thereby causing theflip-flop 512 to Reset whenever the value of the motor current plus rampfrom the summing junction 430 exceeds the value of the error signal fromthe input terminal 504 as applied to the inverting input of thecomparator 502. The Set input of the flip-flop 512, on the other hand,is activated every time the output 408 of the comparator 402 goes low,thereby activating the inverted output of flip-flop 512 at the start ofeach ramp cycle coinciding with the ramp signal received at the summingjunction 430 across the resistor 424. Once activated, the invertedoutput of the flip-flop 512 drives the collector of the drivertransistor 508 high. When the collector of the driver transistor 508 islow, the pwm switch transistor 130 of FIG. 2 is off or non-conducting,and the center tap 110 of the motor 102 is at approximately 0 volts.When the collector of the driver transistor 508 is high, then the pwmswitch transistor 130 is on or conducting, and the center tap 110 of themotor 102 is coupled to V_(in) in FIG. 2. As may be recognized by thoseskilled in the pertinent art based on the teachings herein, the periodicsignal generator may generate any of numerous different periodic or rampsignals suitable for performing the functions described herein.

FIG. 5A depicts a typical prior art pwm voltage regulator motor currentwaveform resulting when motor commutation happens to be ideal. As can beseen, the waveform is symmetrical from pulse to pulse, butnon-symmetrical within each pulse. More frequently however, prior artmotors will exhibit non-ideal commutation with a resultant motor currentwaveform such as that depicted in FIG. 5B. The waveform of FIG. 5B isnon-symmetrical from pulse to pulse in addition to being non-symmetricalwithin each pulse. One advantage of the present invention is that asymmetrical motor current waveform, such as that depicted in FIG. 5C, isattainable via application of the present invention to brushless DCmotors such as those used in the prior art.

In the operation of the apparatus and method of the invention, the motoris powered by the voltage pulses passing across the pwm switchtransistor 130 of FIG. 2 only when the output 510 of the transistor 508is activated. The transistor 508 is activated periodically when theoutput 408 of the comparator 402 goes low, such activationscorresponding to the start of a periodic sawtooth or other ramp signalgenerated by the oscillator or other periodic signal generator. Theoutput 510 is effectively deactivated whenever the sum of the rampsignal at 432 and the motor current signal at 428 exceed the value ofthe error voltage 504 corresponding to the difference between motoractual speed and desired speed. Thus, motor speed is primarilycontrolled by the circuit of FIG. 2, while motor current is primarilycontrolled by the sub-circuit 400 of FIG. 4. The result is accuratemotor speed control accompanied by symmetrical motor current waveforms,such as depicted in FIG. 5C. A further advantage of the symmetricalmotor current waveform of the present invention is that it may haveattendant acoustical benefits when realized in a fan motor controllerfor lower inertia fan assemblies.

Turning now to FIG. 6, a pwm voltage regulator circuit 600 embodying theinvention is employed in an H-bridge modulation approach for regulatingthe rotational speed of a bipolar brushless DC motor winding 622. Themotor is a conventional brushless DC motor which may be coupled to a fanused to cool a surrounding area such as the inside of a computer.

The voltage regulator circuit 600 includes a positive input terminal 624and a negative input terminal 626 for receiving thereacross a DCregulator input signal from a power source (not shown). An inputcapacitor 628 is coupled across the positive and negative inputterminals 624 and 626. Means for switchably passing a motor supplysignal to a brushless DC motor winding 622 includes, for example, afirst pwm switch or transistor 630, and a second pwm switch ortransistor 631, such as the N-channel MOSFETs illustrated. Thetransistor 630 has its drain coupled to the positive input terminal 624via junction terminal 610, its source coupled to an input voltageterminal of the motor winding 622 at terminal 684, and its gate coupledto a first pwm driver terminal 656. The transistor 631 has its draincoupled to the positive input terminal 624 via junction terminal 610,its source coupled to an input voltage terminal of the motor winding 622at terminal 686, and its gate coupled to a second pwm driver terminal657.

The motor winding 622 has a first end coupled to a first input terminal684, and a second end coupled to a second input terminal 686. The firstinput terminal 684 is alternately connected to ground potential via afirst commutation switching transistor 614, and the second inputterminal 686 is likewise alternately connected to ground potential via asecond commutation switching transistor 618. The switching transistors614, 618 are alternately turned on and off by means of a Hall Effectsensor 660. The Hall Effect sensor 660 is coupled to a first outputterminal 662 and a second output terminal 664. Output terminal 662 iscoupled to the gate of a commutation transistor 614, which has its draincoupled to motor input terminal 684. Output terminal 664 is coupled tothe gate of a commutation transistor 618, which has its drain coupled tomotor input terminal 686. The source terminals of commutationtransistors 614 and 618 are coupled together and then coupled to motorcurrent sample terminal 682. Terminal 682 is dropped across resistor 680to negative input terminal 626, which is coupled to ground potential.Negative V_(CC) potential is coupled to the anode of a diode 672, thecathode of which is connected to driver power terminal 668. Terminal 668is coupled to bootstrap capacitor 676 which is then coupled to motorinput terminal 684. Negative V_(CC) potential is also coupled to theanode of a diode 674, the cathode of which is connected to driver powerterminal 670. Terminal 670 is coupled to bootstrap capacitor 678 whichis then coupled to motor input terminal 686. The motor winding 622 iscaused to rotate by interacting with an electromagnetic field generatedby commutated current flowing therethrough.

Turning to FIG. 7, a preferred embodiment of the pulse width modulatorfor a bipolar motor is indicated generally by the reference numeral 650.The pwm 650 includes a voltage sub-circuit 760, a periodic sub-circuit770, and a driver sub-circuit 780 each enclosed by dashed lines.

The voltage sub-circuit 760 comprises means for averaging the voltage ofthe motor supply signal including series connected resistors 636 and637, and an averaging capacitor 638 which cooperate to form a voltageaveraging circuit. The resistor 636 is coupled between motor windingterminal 684 and terminal 644, and the resistor 637 is coupled betweenmotor winding terminal 686 and junction 644. The averaging capacitor 638is then coupled between junction 644 and ground potential. A firstvoltage dividing resistor 647 is coupled between junction 644 and theinverting input of an error amplifier 646. A second voltage dividingresistor 649 is coupled between the inverting input of the erroramplifier 646 and ground potential. The non-inverting input to the erroramplifier 646 is coupled to a reference voltage V_(REF). The output ofthe error amplifier 646 is coupled to a voltage error terminal 652. Acapacitor 657 is coupled between the terminal 652 and the invertinginput to the error amplifier 646. A resistor 820 is coupled betweenterminal 652 and terminal 804. A resistor 822 is coupled betweenterminal 804 and ground.

Means for generating a differential signal at terminal 652 having avoltage level indicative of the difference between the voltage level ofthe averaged signal and a reference voltage includes the high gainoperational or error amplifier 646, which in the preferred embodiment ofthe present invention is a differential voltage amplifier. The erroramplifier 646 has its inverting input coupled to the junction 644 via aresistor 647. The gain of the error amplifier 646 is preferably selectedso that only millivolts of difference between the inverting andnon-inverting inputs will drive the amplifier output to its extreme. Aresistor 649 is coupled between the inverting input of the erroramplifier 646 and ground potential. The non-inverting input of the erroramplifier 646 is fed the reference voltage V_(REF). An output terminal652 of the error amplifier 646 is coupled to the driver sub-circuit 780at terminal 804. The pwm 650 provides a means for turning on and off thepwm switching transistors 630 and 631 of FIG. 6 to modulate the motorsupply signal so that the motor supply signal is maintained at asubstantially constant voltage level and, in turn, the motor winding 622is maintained at a substantially constant rotational speed. A roll-offcapacitor 657 is coupled between the inverting input and the output ofthe error amplifier 646.

The periodic sub-circuit 770 comprises a periodic signal generator inthe form of an oscillator comprising a comparator 702 and relatedcircuit components. The comparator 702 has its non-inverting inputcoupled to a V_(cc) source at 704 via a resistor 706. An output 708 ofthe comparator 702 is coupled to its non-inverting input via a resistor710. A resistor 712 is coupled between the non-inverting input of thecomparator 702 and ground potential. The resistors 706, 710 and 712 arecoupled to one another at a junction 714. A timing resistor 722 iscoupled between the output 708 of the comparator 702 and the cathode endof a diode 720. The anode end of the diode 720 is coupled to theinverting input of the comparator 702. A timing resistor 716 is coupledbetween the output 708 and the inverting input of the comparator 702. Atiming capacitor 718 is coupled between the inverting input of thecomparator 702 and ground potential. A resistor 724 is coupled betweenthe inverting input of the comparator 702 and a summing junction 730. Asdescribed in further detail below, the periodic signal generatortransmits a ramp signal to the junction 732 defining a sawtoothwaveform. However, as may be recognized by those skilled in thepertinent art based on the teachings herein, the periodic signalgenerator may generate any of numerous different periodic or rampsignals suitable for performing the functions described herein.Similarly, the periodic signal generator may take any of numerousdifferent configurations which now or later become known to thoseskilled in the pertinent art for performing the functions of theperiodic signal generator described herein.

Means for receiving a motor current sample signal are provided by aninput terminal 682. The input terminal 682 may be coupled, for example,to the source terminals of the commutation switch MOSFETs of FIG. 6.However, as may be recognized by those skilled in the pertinent artbased on the teachings herein, the input terminal 682 for receiving themotor current input signal may be coupled to any of numerous other motorcurrent sources for generating the motor current signal describedherein. A resistor 726 is coupled between the input terminal 682 and thesumming junction 730. Accordingly, the summing junction 730 provides asignal indicative of the sum of the periodic or ramp signal receivedfrom junction 732 and the motor current signal received from the inputterminal 682.

The driver sub-circuit 780 includes a comparator 802 having itsinverting input coupled to the summing junction 730 of the periodicsub-circuit 770. The non-inverting input of the comparator 802 receivesat terminal 804 the error voltage signal from the output 652 of theerror amplifier 646 of FIG. 6. An output 806 of the comparator 802 iscoupled to a Reset input of an RS flip-flop 812. The Set input offlip-flop 812 is coupled to the output 708 of the periodic sub-circuit700. The non-inverting output of the flip-flop 812 is coupled tojunction 824. NAND gate 826 receives inputs from junction 824 and Halloutput terminal 664, and has its output coupled through a resistor 814to the base of a transistor 808. An emitter of the transistor 808 iscoupled to ground potential, and a collector of the transistor 808 iscoupled at its output 810 to the input 656 of the power transistor 630of FIG. 6. NAND gate 828 receives inputs from junction 824 and Halloutput terminal 662, and has its output coupled through a resistor 815to the base of a transistor 809. An emitter of the transistor 809 iscoupled to ground potential, and a collector of the transistor 809 iscoupled at its output 811 to the input 657 of the power transistor 630of FIG. 6. The transistors 808 and 809, which serve as pwm drivertransistors, are shown as npn BJTs, but may be FETs or other suitabletransistors or other electrical conduction switches for driving thepulse width modulators of the invention. Similarly, as may be recognizedby those skilled in the pertinent art based on the teachings herein, theflip-flop 812 may take the form of any of numerous binary state or likedevices which now or later become known to those skilled in thepertinent art for performing the functions of the flip-flop describedherein.

When the output of the comparator 702 is low, the junction 714 of theresistors 706, 710 and 712 may be at ⅓ V_(cc). When the output of thecomparator 702 is high, the junction 714 may be at ⅔ V_(cc). The timingcapacitor 718 is periodically charged, for example, from ⅓ V_(cc) to ⅔V_(cc) by the timing resistor 716. The timing capacitor 718 isperiodically discharged from ⅔ V_(cc) to ⅓ V_(cc) by the timing resistor722 through diode 720. The frequency of oscillation is primarily afunction of the capacitance level of the timing capacitor 718 and theresistance levels of the timing resistors 716 and 722. Timing resistor716 determines the charge period, and the equivalent resistance ofparallel resistors 716 and 722 determines the discharge period.Accordingly, a ramp voltage generated by the timing resistor 716 and thetiming capacitor 718 is applied to the junction 732 and, in turn, to thesumming junction 730. Input terminal 682 passes a motor current signalacross resistor 726 to summing junction 730. Thus, the resultant signalat the summing junction 730 is approximately equal to the sum of theramp signal and the motor current signal, and the summed signal iscoupled to the non-inverting input of the comparator 802 of the driversub-circuit 780. The output terminal 806 of the comparator 802 iscoupled to the Reset input of the flip-flop 812, thereby causing theflip-flop 812 to Reset whenever the value of the motor current plus rampfrom the summing junction 730 exceeds the value of the error signal fromthe input terminal 804 as applied to the inverting input of thecomparator 802. The Set input of the flip-flop 812, on the other hand,is activated every time the output 708 of the comparator 702 goes low,thereby activating the inverted output of flip-flop 812 at the start ofeach ramp cycle coinciding with the ramp signal received at the summingjunction 730 across the resistor 724. Once activated, the non-invertedoutput of the flip-flop 812 drives the collector of one of the drivertransistors 808 or 809 high. When the collector of the driver transistor808 is low, the pwm switch transistor 630 of FIG. 6 is conducting to lowpotential. When the collector of the driver transistor 808 is high, thenthe pwm switch transistor 630 is conducting from high potential.Likewise, when the collector of the driver transistor 809 is low, thepwm switch transistor 631 of FIG. 6 is conducting to low potential. Whenthe collector of the driver transistor 809 is high, then the pwm switchtransistor 631 is conducting from high potential.

As may be recognized by those skilled in the pertinent art based on theteachings herein, the periodic signal generator may generate any ofnumerous different periodic or ramp signals suitable for performing thefunctions described herein.

Referring now to the method of operation of the pwm voltage regulatorcircuit 600 shown in FIG. 6, the two lower MOSFETs 614 and 618 areenergized in response to the Hall Effect Sensor 660, which provides twooutputs 662 and 664 that are out of phase with each other. As may bereconfigured by those skilled in the pertinent art based on theteachings herein, this function also could be performed by a singleoutput Hall Switch with an inverting buffer, a Hall element withsuitable amplifier, or some other type of position sensor such as anopto/electric sensor. The purpose being to activate the associatedtransistor switch. Here, outputs are shown that are used to gate the PWMswitches 630 and 631. Alternatively, the output of the position sensorcould be used to gate the synchronous switching of lateral pairs forgreater power efficiency.

The direction of the current in the motor winding 622 is determined bythe appropriate activation of opposing transistor pairs 614 and 631, or618 and 630. For example, when PWM Switch 630 and Commutation Switch 618are “ON”, then one might say that the motor winding is energized “+ to−.” When the opposite case occurs where PWM Switch 631 and CommutationSwitch 614 are “ON”, the winding would be energized “− to +.” Byrepeating this sequence the motor is caused to rotate, and by thereversing of the current the motor is caused to be a bipolar motor.

Motor current is dropped across the resistor 680 to produce a smallvoltage at terminal 682 that is used to detect the amplitude of themotor current. This voltage representing the motor current is to be usedin the course of regulating the motor current during normal and faultconditions. The MOSFETs 614, 618, 630 and 631 are N-channel types butcould, by appropriate circuit design, be a mixture of P-channel andN-Channel types or some other type of solid state devices such asbipolar transistors or IBGTs.

For the power circuits to function properly in this embodiment a biassource of sufficient amplitude, about 10 volts higher than +Vin, must beprovided to the upper side PWM switches 630 and 631. This isaccomplished with the use of bootstrap drivers comprising the bootstrapcapacitors 676 and 678, and the rectifier diodes 672 and 674. When thePWM switch 630 or 631 is “OFF”, then that PWM switch Source lead whichhas a common connection with the bootstrap capacitor 676 or 678 is atapproximately ground potential. The other end of the bootstrap capacitoris connected to −Vcc through the associated rectifier 672 or 674. Whenthe PWM switch 630 or 631 is “ON”, the PWM Switch Drain and Source areboth at nearly Vin potential. The bootstrap capacitor 676 or 678 whichwas charged to Vcc is now at Vcc+Vin. This provides the necessaryvoltage to energize the PWM Switch 630 or 631.

With reference to FIG. 7, the oscillator is composed of the comparator702, the resistor divider network comprising resistors 706, 710 and 712,and a time constant network. The values of the resistors 706, 710 and712 determine the oscillator ramp levels at terminal 732 which for a10-volt Vcc could be around 2 volts for a ramp voltage valley and around7 volts for a ramp voltage peak.

The relative ratios for the charging resistor 716 and the dischargingresistor 722 could be approximately 50:1. Ramp signal frequency is thendetermined primarily by charging resistor 716 and timing capacitor 718and could be in the area of 20 kHz. The ramp signal from terminal 732 issummed at summing junction 730 with the Motor Current Sample fromterminal 682 and applied to the inverting input of the second comparator802.

In order to accurately maintain motor speed over a variety of inputvoltages V_(IN) and to minimize the variation between production motorsit is desirable to use a voltage control loop. A constant voltage driveis believed to maintain motor speed better than a constant current driveover different load conditions, such as back pressure variations or airdensity differences, because the motor is allowed to draw more currentand therefore do more or less work as required. Constant voltage drivealso results in less speed variation from motor to motor under equalloading conditions because variations from motor to motor are expressedas differences in input current for each individual motor. A welldesigned constant current drive can, however, result in less currentvariation within the rotational period of the motor.

By imbedding a current control loop within a voltage control loop inaccordance with the invention optimal characteristics can be obtained.In other words, the voltage loop maintains a more equal speed overvarying load conditions and minimizes speed deviations between differentmotors, and the current loop maintains a substantially constant currentwithin the rotational period.

To accomplish the voltage control the present invention compares themotor voltage against a reference level. This is done by differentialamplifier 646 that has the non-inverting terminal connected to areference voltage. For the purpose of example that reference could be0.25 volts. The motor voltage is derived with an averaging capacitor 638and two resistors 636 and 637 attached to either end of the motorwinding. The voltage on the capacitor 638 is equal to about ½ of theactual motor voltage. The divider network comprised of resistors 647 and649 then scales that averaged voltage to be equal to the same 0.25 voltson the inverting terminal of the differential amplifier at the desiredreal motor voltage level.

The gain of the amplifier 646 is very high such that typically less than1 mv of difference between inputs will result in several volts of changein the output. This output voltage, referred to as the Error voltage, isin turn applied to the non-inverting input of a comparator throughdivider resistors 820 and 822. This is to scale the full output voltageof the operational amplifier (646-842) to about 0.3 volts for 7.5 voltson the output 806 of the amplifier 802.

The motor current sample at terminal 682, which has a level of about 0.2volts for full load operation, is summed at junction 730 with a portionof the ramp obtained from the oscillator and applied to the invertinginput of the comparator 802. This causes the output of the comparator togo “LOW” when the instantaneous value of the motor sample plus rampexceeds the voltage level set by the Error amplifier 802.

The output of the oscillator comparator 702 is “LOW” when the oscillatortiming capacitor 718 is discharged, and this is connected to the “Set”input of flip-flop 812 so as to “Set” the flip-flop at the end of eachoscillator cycle. The output of the comparator 802, which compares thecurrent sample to the Error voltage, is connected to the Reset input ofthe flip-flop 812. The “Q” output of the flip flop 812 will then be“HIGH” when the oscillator starts the timing cycle, and will go “LOW”when the current sample exceeds a level determined by the voltage erroramplifier 802.

The output or the flip-flop 812 is then applied to the inputs of twoNAND gates 826 and 828 that also receive inputs from the Hall EffectSwitch 660. The NAND gates route the flip flop output to the appropriatedrive transistor 808-809 according to the motor position as sensed bythe Hall Effect Switch 660, which in turn enables the appropriate PWMMOSFET 630 or 631. Accordingly, the comparator 802 controls the currentin the motor by affecting interruption of current flow through the PWMMOSFETs 630 or 631. This occurs when the current exceeds a level set bythe Voltage Error amplifier 646. The amplitude of the motor current isdetermined by comparing the motor voltage against a desired value butnevertheless will remain substantially constant over the rotationperiod.

FIGS. 8A and 9A depict typical prior art pwm voltage regulator motorinput current waveforms resulting at motor speeds of about 2000 and 3500RPM respectively. As can be seen, the input waveforms arenon-symmetrical within each pulse and non-symmetrical between cycles.One advantage of the present invention is that substantially symmetricalmotor input current waveforms, such as those depicted in FIGS. 8B and9B, are attainable via application of the present invention to brushlessDC motors such as those used in the prior art.

FIGS. 10A and 11A depict typical prior art pwm voltage regulator motorwinding current waveforms resulting at motor speeds of about 2000 and3500 RPM respectively. As can be seen, the motor winding waveforms arenon-symmetrical within each pulse and non-symmetrical between cycles.Another advantage of the present invention is that symmetrical motorwinding current waveforms, such as those depicted in FIGS. 10B and 11B,are attainable via application of the present invention to brushless DCmotors such as those used in the prior art.

Those skilled in the pertinent art may recognize, based on the teachingsherein, that the aforementioned method of motor speed regulation may beapplied to time-varying motor control with relative ease by applicationof a time-varying motor reference signal to the present invention.Accordingly, the method of the present invention may further comprisethe steps of controlling a pulse width of the pulsed motor supply signalto control the average voltage level of the pulsed motor supply signalin response to a control input via the reference voltage correspondingto a desired change in the angular velocity of the motor.

Accordingly, although this invention has been shown and described withrespect to exemplary embodiments thereof, it should be understood bythose skilled in the art that the foregoing and various other changes,omissions, and additions in the form and detail thereof may be madetherein without departing from the spirit and scope of the invention.

What is claimed is:
 1. A method of regulating the rotational speed of aDC brushless motor having at least one input terminal, a plurality ofmotor windings electrically coupled to the at least one input terminal,and a rotor defining a rotor mass and electromagnetically coupled to themotor windings and rotatable by interaction with an electromagneticfield generated by current flowing through the motor windings, themethod comprising the following steps: passing motor supply signals froman electrical power source through an electrical conduction switchhaving an input, an output, and a control terminal; pulse widthmodulating the motor supply signals passing through the electricalconduction switch and generating pulse width modulated motor supplysignals; transmitting the pulse width modulated motor supply signalsthrough a substantially inductorless path extending from the output ofthe electrical conduction switch to the at least one input terminal;using the windings of the motor to integrate the pulse width modulatedmotor supply signals and function as an inductor filter to smooth thecurrent level of the motor supply signals; and using the rotor mass as afilter capacitor to smooth the voltage level of the motor supplysignals.
 2. A method as defined in claim 1, further comprising the stepof transmitting the pulse width modulated motor supply signals through asubstantially inductorless path extending from the output of theelectrical conduction switch to a center tap input terminal of the DCbrushless motor.
 3. A method as defined in claim 1, further comprisingthe steps of generating a differential signal having a voltage levelindicative of the difference in voltage between a voltage levelcorresponding to the voltage level of at least one motor supply signaland a reference voltage, and pulse width modulating the motor supplysignal in response to the value of the differential signal to furtherprovide a substantially constant voltage level of the motor supplysignal.
 4. A method defined in claim 3, further comprising the step ofaveraging a voltage level of at least one motor supply signal,generating an approximately averaged signal, and generating thedifferential signal based on the averaged signal.
 5. A method as definedin claim 4, further comprising the step of reducing the voltage level ofthe averaged signal, and wherein the generating step further comprisesgenerating a voltage level indicative of the difference in voltagebetween the reduced voltage level of the averaged signal and thereference voltage.
 6. A method as defined in claim 3, further comprisingthe steps of: (a) at least one of (i) increasing a pulse width of themotor supply signal to increase the voltage level of the motor supplysignal to a selected voltage level corresponding to a selected motorspeed; and (ii) decreasing the pulse width of the motor supply signal todecrease the voltage level of the motor supply signal to a selectedvoltage level corresponding to a selected motor speed; and (b)modulating the step of passing the motor supply signal in response tothe value of the differential signal to further provide a substantiallyconstant selected voltage level to maintain the selected motor speed. 7.A method as defined in claim 1, further comprising the step oftransmitting the pulse width modulated motor supply signals through asubstantially inductorless and capacitorless path extending from theoutput of the electrical conduction switch to a center tap inputterminal of the DC brushless motor.
 8. A control circuit for regulatingthe rotational speed of a DC brushless motor having at least one inputterminal, a plurality of motor windings electrically coupled to the atleast one input terminal, and a rotor defining a rotor mass andelectromagnetically coupled to the motor windings and rotatable byinteraction with an electromagnetic field generated by current flowingthrough the motor windings, the control circuit comprising: anelectrical conduction switch having an input, an output and a controlterminal for passing a motor supply signal to the DC brushless motorfrom a voltage across first and second terminals of a DC voltage source,the input terminal of the switch being coupled to the first terminal ofthe DC voltage source, and the output terminal of the switch beingcoupled to the at least one input terminal of the motor; a substantiallyinductorless path extending from the output of the electrical conductionswitch to the at least one input terminal of the motor; a pulse widthmodulator having an output terminal coupled to the control terminal ofthe electrical conduction switch for pulse width modulating the motorsupply signals passing through the electrical conduction switch andgenerating pulse width modulated motor supply signals, wherein: thepulse width modulated motor supply signals are transmitted through thesubstantially inductorless path extending from the output of theelectrical conduction switch to the at least one input terminal; thewindings of the motor integrate the pulse width modulated motor supplysignals and function as an inductor filter to smooth the current levelof the motor supply signals; and the rotor mass functions as a filtercapacitor to smooth the voltage level of the motor supply signals.
 9. Acontrol circuit as defined in claim 8, further comprising: adifferential (error) amplifier having first and second input terminalsand an output terminal for generating a differential signal having avoltage level indicative of the difference between a voltage levelcorresponding to the voltage level of the motor supply signal and areference voltage, the first input terminal of the differentialamplifier being coupled to a voltage reference, and the second inputterminal of the differential amplifier being coupled to the outputterminal of the switch; and wherein the input terminal of the pulsewidth modulator is coupled to the output terminal of the differentialamplifier, such that the pulse width modulator generates a modulatedsignal having a pulse width indicative of the voltage level of thedifferential signal to turn the switch on and off to modulate the motorsupply signal and further generate a substantially constant selectedvoltage level to the motor supply signal.
 10. A control unit as definedin claim 8, further defining a capacitorless path extending from theoutput of the electrical conduction switch to a center tap inputterminal of the DC brushless motor, and wherein the pulse widthmodulated motor supply signals are transmitted through the substantiallyinductorless and capacitorless path extending from the output of theelectrical conduction switch to a center tap input terminal of the DCbrushless motor.
 11. A control circuit as defined in claim 8, furthercomprising a DC brushless motor.
 12. A control circuit as defined inclaim 8, wherein the electrical conduction switch is a power transistor.13. A control circuit for regulating the rotational speed of a DCbrushless motor having at least one input terminal, a plurality of motorwindings electrically coupled to the at least one input terminal, and arotor defining a rotor mass and electromagnetically coupled to the motorwindings and rotatable by interaction with an electromagnetic fieldgenerated by current flowing through the motor windings, the controlcircuit comprising: first means coupled to an electrical power sourcefor switchably passing a motor supply signal to the at least one inputterminal of the DC brushless motor; second means for pulse widthmodulating the motor supply signals passing through the electricalconduction switch and generating pulse width modulated motor supplysignals; third means for transmitting the pulse width modulated motorsupply signals through a substantially inductorless path extending fromthe output of the electrical conduction switch to the at least one inputterminal; fourth means within the windings of the motor for integratingthe pulse width modulated motor supply signals and functioning as aninductor filter to smooth the current level of the motor supply signals;and fifth means within the rotor for functioning as a filter capacitorto smooth the voltage level of the motor supply signals.
 14. A controlcircuit as defined in claim 13, further comprising: means coupled to anoutput of the first means for generating a differential signal having avoltage level indicative of the difference between a voltage levelcorresponding to the voltage level of the motor supply signal and areference voltage; and wherein the second means turns on and off thefirst means in response to the value of the differential signal.
 15. Acontrol circuit as defined in claim 13, further comprising means fortransmitting the pulse width modulated motor supply signals through acapacitorless path extending from the output of the electricalconduction switch to a center tap input terminal of the DC brushlessmotor.
 16. A control circuit as defined in claim 15, wherein said meansis a capacitorless connection extending from the output of theelectrical conduction switch to the at least one input terminal.
 17. Acontrol circuit as defined in claim 13, further comprising a DCbrushless motor.
 18. A control circuit as defined in claim 13, whereinthe fourth means is the windings of the motor.
 19. A control circuit asdefined in claim 13, wherein the rotor defines a rotor mass, and thefifth means is the mass of the rotor.
 20. A control circuit as definedin claim 13, wherein the first means is an electrical conduction switch.21. A control circuit as defined in claim 13, wherein the third means isan inductorless connection extending from the output of the electricalconduction switch to the at least one input terminal.